A New PFC CCM Boost Rectifier with Extended Gain and Reduced Voltage Switching for 1-ph/3-ph Universal Input On-Board Charger for Electric Vehicles

A new power-factor-correction (PFC), continuous-conduction-mode (CCM) bidirectional boost rectifier for 1-ph/3-ph universal voltage input on-board charging applications is introduced. The rectifier features extended voltage gain, automatic input current sharing, and reduced voltage switching when it operates from 1-phase input voltage. Due to the extended-gain property, the proposed topology is suitable for converting low line voltages to a high dc link voltage. Switching at reduced voltage results in decreased switching losses, which allows the converter to achieve significantly increased power conversion efficiency. Unlike in standard interleaved PFC topologies, input current sharing is achieved without any sensing circuits or additional control loops. The evaluation was performed on a 3.3 kW prototype designed to operate from 85-134 V line input and deliver 775 V dc output. The prototype achieves 93.6% efficiency at 110 VRMS line input and full load. The proposed converter naturally morphs into the standard 6-switch converter for 3-phase ac voltage inputs.